DE10221374A1 - Production of polytrimethylene terephthalate (PTT) carpets of improved quality, avoiding excessive thread thickness and giving increased nap resilience - Google Patents

Abstract

A process for production of polytrimethylene terephthalate (PTT) carpets including the steps: (A) twisting of PTT threads; (B) heat curing the threads; (C) bunching or tufting of the heat cured PTT threads; (D) vat dyeing the bunched or tufted carpet without a carrier using a dispersion dye; (E) strengthening of the underside of the dyed carpet; and (F) clipping of the finished carpet is new. A process for production of polytrimethylene terephthalate (PTT) carpets including the steps: (A) twisting of PTT threads, (B) heat curing the threads of thickness 200-240 g/cm using a Superba (RTM; saturated steam continuous heat setting) machine of main tunnel temperature 120-160 deg C and a belt velocity of 4-9 m/min, (C) bunching or tufting of the heat cured PTT threads at 5-15 stitches/2.54 cm, (D) vat dyeing of the bunched or tufted carpet without a carrier using a dispersion dye at atmospheric pressure and 90-100 deg C, (E) strengthening of the underside of the dyed carpet, and (F) clipping of the finished carpet. An Independent claim is included for a PTT carpet produced as above, with a stretching or tensile strength of 2.0 kg or more, the bonded fabric having an extraction resistance of 2.0 kg or more, color fastness to washing, rubbing, and light, in accordance with rating 4 of the Korean Technical Standards.

Description

The invention relates to a method for producing a Poly (trimethylene terephthalate) (PTT) carpet and in particular a process for producing a poly (trimethylene tereph thalat) carpet, its quality, functionality and bear processability by optimizing the machining conditions summarizing the twisting, the heat hardening, the tufts or Tufting, dyeing, back reinforcing and shaving ren have been improved.

For carpets that are susceptible to staining by usual Food dyes are resistant, currently exists high demand. In order to become stain resistant, Nylontep either with a stain resistance chemical must be traded or into the polymer of the nylon fibers Stain resistance agents can be incorporated.

They are carpets made with polyester fibers excellent stain resistance like polyethylene tereph thalate) or poly (butylene terephthalate) have been developed. So describe e.g. See, for example, U.S. Patents 3,998,042 and 4,877,572 a Ver drive to manufacture a poly (ethylene terephthalate) BCF Yarn. Carpets made from this yarn have good stain resistance, but show Bad due to low elastic springback Pile springback and poor texture retention. Therefore poly (ethylene terephthalate) yarns are currently hardly used det.

To overcome the disadvantages of the aforementioned poly (ethylene terephthalate) carpet is already a technology  position of a carpet made of a poly (trimethylene terephthalate lat) yarn has been developed. For example, B. the U.S. Patent 5,662,980 carpets made from bulky poly (trimethy lenterephthalate) continuous filament yarns with a modified cross-section, where the bauschi used to make the carpet against continuous poly (trimethylene terephthalate) yarns Marked stain resistance, as well as a good bend back have suspension and pile height retention. Furthermore, the has Modified poly (trimethylene terephthalate) (BCF) yarns Cross-sectioned carpet maintains good texture or texture retention.

However, the materials described above have the disadvantage that because after a feed roller spin finish materials be piled up on the threads by the feed pass through the roller, a lot of friction is exerted, which leads to many yarn cuts or yarn breaks and thus to egg poor processability. Another disadvantage results from yarn compression or yarn compression, that at high temperatures using a compaction device processing with simultaneous operation of a texturing device tion is carried out. That is why the yarns are so bad seals or pressed together that the Flors during the Postprocessing method too frayed and that the Carpet has a bad appearance.

Furthermore, US Pat. No. 5,662,980 includes various Factors related to the heat treatment level only the main ones tunnel temperature specified, but other factors such as the retention time in the main tunnel and the density of the not processed yarn on a belt cannot be specified, so that an optimal heat treatment is not carried out that can.  

The object of the invention is therefore the disadvantages of the stand the technology to overcome and a new method to manufacture provision of a poly (trimethylene terephthalate) carpet deliver, its quality, functionality and workability speed by optimizing the processing conditions of the night processing methods comprising twisting, heat harden, tufting, tinting, dyeing, the back Reinforcing and shearing have been improved.

Another object of the invention is to provide egg Process for the production of a poly (trimethylene tereph thalat) carpet in terms of its physical egg properties including the peel strength, the tensile strength activity and dimensional stability of conventional carpets is equivalent or superior. The carpet should continue excellent machinability in post processing have to drive.

The invention relates to a process for producing a poly (trimethylene terephthalate) carpet, comprising the steps:

• A) twisting poly (trimethylene terephthalate) yarns;
• B) Heat hardening of the twisted poly (trimethylene terephthalate lat) yarns with a density of 200 to 240 g / m below Using a Superba machine on a main tunnel temperature of 120 to 160 ° C and a belt speed speed from 4 to 9 m / min.
• C) Tufts or tufts of the thermoset poly (trimethy lenterephthalate) yarns at 5 to 15 stitches / 2.54 cm;
• D) vat dyeing of the tufted or tufted carpet without a carrier using a disperse dye  under conditions of atmospheric pressure and dyeing temperature from 90 to 100 ° C;
• E) reinforcing the back of the colored carpet; and
• F) shearing the resulting carpet.

The invention will become more apparent from the accompanying drawings explained. Show it

Figure 1 shows the modification ratio and the arm angle of a poly (trimethylene terephthalate) carpet made of yarn with a modified cross-section according to the present invention.

Fig. 2 shows schematically the production of a poly (tri methylene terephthalate) carpet from yarn with a modified cross section according to the invention and

Fig. 3 is a diagram schematically illustrating the manufacture of a poly (trimethylene terephthalate) carpet according to the inven tion.

The carpet according to the invention is made of poly (trimethylene tereph thalat) yarns. The carpet has an excellent springback, stain resistance and coloring properties against dispersion properties. He also has one excellent elastic recovery and pile height retention tion or pile height retention compared to a poly (ethy lenterephthalate) carpet or a poly (butylene terephthalate) lat) carpet. Accordingly, the poly (tri methylene terephthalate) carpet as a high quality Carpet suitable for use in living rooms or offices. Furthermore, the carpet according to the invention can be used as a pile carpet, Loop pile carpet, as a combination carpet, as a mat and be made as a simple carpet.  

With reference to Fig. 2, the production of poly (trimethylene terephthalate) yarns with a modified cross section will now be described, which are used to produce the carpets according to the invention.

A PTT polymer with an intrinsic or intrinsic viscosity of 0.8 to 1, 2 and a moisture content of 50 ppm or less is melt-spun at 245 to 265 ° C through a spinneret or a spinning head 1 . The nozzle has a Y-shaped cross section, 40 holes or more, a modification ratio of 1.5 to 3.5 and an arm angle of 5 to 40 °. If the modification ratio and the arm angle are within the above ranges, then the PTT yarns have excellent properties in terms of volume property, spinning efficiency and tufting efficiency.

In Fig. 1, "modification ratio" means the ratio of the diameter R of the circumscribing or defining circle to the diameter r of the inscribing circle of a continuous yarn of unprocessed yarns with a Y-shaped cross section. That is, Modification ratio = R / r. "Arm angle" is to be understood to mean an acute angle which is formed by two elongated lines from both edges or edges of an arm of a continuous yarn of untreated yarns with a Y-shaped cross section.

Then the spun continuous yarns 2 , which move at a speed of 0.4 to 0.6 m / min, are cooled in a cooling zone 3 to 10 to 25 ° C and subjected to a spin finish stage in which the cooled yarns using a knitting type or a water-soluble oiling agent are oiled through two phases in an applicator 4 , so that the lubricating properties and the smoothness of the yarns are increased and that the yarns are highly compressed or compressed.

The resulting yarns are then passed through a nozzle or spinning head 5 for drawing in yarns which pull in the threads which are torn during the spinning. You will be using a feed roller 6 with a Ge speed of 650 to 850 m / min and at a temperature of 45 to 80 ° C and a tension roller 7 with a speed of 1500 to 4000 m / min and a temperature of 140 to 180 ° C stretched. The continuous yarns are crimped at 180 to 220 ° C. under 5 to 8 kg / m ² in a texturing device 8 after the continuous yarns have passed through the drawing or drawing roller 7 . The crimp is 10 to 60%.

Next, the continuous yarns are cooled to 15 to 22 ° C. by a cooling drum 9 and twists and knots of 10 to 40 times / m are transferred to the yarns at 4.5 to 5.0 kg / m ² by a whirling machine 11 on the way awarded a guide roller 10 . In this way, the yarns are highly compressed or compressed. If the twists are given a twist of 10 times / m or less, fluffiness or capillary problems arise because the untreated yarn has been poorly compressed. In this way, the cutting efficiency of the untreated yarn during crimping or tufting is reduced, so that the shorn carpet has a poor appearance due to fraying of the pile ends. The load-bearing capacity of the carpet is also reduced.

On the other hand, if the continuous yarns are twisted at 40 times / m or more, the carpet has a bad appearance because the threads remain knotted even after dyeing and finishing. Thereafter, the yarns are wound up using a winder on the way about a fifth guide roller 12 and a yarn guide 13 . The speed of the rewinder 14 is determined according to the speed of the fifth guide roller 12 and is preferably 1400 to 3500 m / min.

The poly (trimethylene terephthalate) carpet according to the invention can be made according to the use of the carpet from one spun dyed yarn. Generally have spun-dyed yarns have excellent stain resistance and wear resistance and they can be used for carpets that are used in offices. However, can Carpets that have undergone piece dyeing in also suitable as high quality carpets for living rooms or hotels are used.

The manufacturing process for the carpet from spun-dyed Poly (trimethylene terephthalate) yarns according to the invention the same as the manufacturing process described above for carpets made of common poly (trimethylene terephthalate) - Yarns with the exception that a basic dye bath with 2 to 5% mixed on a basic chip with the raw materials is what these are spun on. The so made Carpet has better color fastness than washing, Color fastness to light and color fastness to Rei ben as carpets that have been subjected to piece dyeing are, the error rate is low because hardly any Banding occurs.

The poly (trimethylene terephthalate) yarns according to the invention post-processing processes such as twisting, a Heat hardening, a tuft, a dyeing, a reinforcement on the back or the application of a carrier fabric bes and sheared to make a carpet put.  

Fig. 3 is a schematic diagram of the manufacturing process according to the Invention for poly (trimethylene terephthalate) carpets.

The yarns are twisted in the twisting stage or twisted (S1). Using a twist twist The yarns are set up at 180 to 250 twists gen / m to two- or three-layer strands S- or Z twisted. In this case, the UPM value is the twist tion device preferably in the range of 4000 to 4300.

Next, the twisted yarns are thermoset (S2). In general, the heat curing device can be an Au toklav, a Seussen machine or a Superba machine his. According to the invention, a Superba machine is preferred used. The twisted yarns with a density of 200 to 240 g / m will preferably be at a main tunnel temperature from 120 to 160 ° C and a belt speed from 4 to 9 m / min thermoset using steam.

For example, if the temperature is less than 120 ° C, then the ends or edges of the pile are quickly removed frayed, which gives a bad appearance because the yarns are not sufficiently thermoset, although the Bulky properties are good. If, on the other hand, the Temperature is higher than 160 ° C, then the bulky properties too poor to allow high bulk receive. If the tape speed and the Density differ from the above range, then the physi calic properties of thermoset yarns poor.

The heat setting stage can still be a frieze Processing before hardening using steam include, giving the carpet a three-dimensional look and an effect of two different colors with one  shows a positive aesthetic appearance. Also the hardness properties and the wear resistance of the pile is increased and the feeling of volume is also improved.

The yarns can be made into two- or three-layer ropes or Cables using an entangling machine at 400 up to 1000 m / min and a pressure of 4 to 8 bar accordingly using the carpets. After that the yarns tufted or tufted without heat hardening.

Then the heat-cured yarns are applied to a spun PET binding or PP base cloth using a 1/8, 5/32 and 1/10 gauge (S3) tufting machine. The range of stitches is 5 to 15 stitches / 2.54 cm. The pile height is in the range of 4 to 18 mm for a pile carpet and from 2.5 to 15 mm for a loop pile carpet. The weight of the untreated yarn used to make the carpets is in the range of 10 to 90 oz / yd ² . For example, the weight and volume perception are bad at 5 stitches / 2.54 cm or less. On the other hand, at 15 stitches / 2.54 cm or more, the stretch and peel strengths are drastically reduced because the yarns do not adhere uniformly to the base fabric during the back reinforcement.

Next, the tufted carpet is made without Carrier using a disperse dye at Be conditions, atmospheric pressure and dyeing temperature from 90 to 100 ° C (S4) vat-colored. For example, if the temperature is less than 90 ° C, then no carpet with ge desired colors can be produced because the yarns are thin are colored. On the other hand, if the temperature is higher than 100 ° C then the production cost will be increased because the yarn should be dyed under high pressure. The OWF value (Amount of dye added based on the carpet)  is 0.01 to 3.0%. The liquid ratio is 10: 1 to 25: 1. The amount of the dispersant is in Range from 0.25 to 1.0 g / l.

There can also be another staining process, namely the room dyeing, can be applied to the poly (trimethylene terephthalate lat) yarns using an MCD (multicolor dye) -Ma shine in a single color or in six or less Colors are dyed before heat curing.

In the step of reinforcement on the back (S5), the colored carpet is coated on the back with latex so that the pile does not come off. This is followed by gluing to a second base cloth such as jute and a polypropylene base cloth, using PVC or SBS (styrene-butadiene-styrene) as an auxiliary mat, ie reinforcement on the back. The solids content of the latex is 80%. In detail, the latex contains 30 to 50% base latex, 50 to 70% CaCO ₃ , dispersing agent and viscosity increasing agent. A small amount of Al ₂ O ₃ or Al ₂ (OH) ₃ can be added to the latex to increase a reverse effect.

To improve the appearance of the pile, the pile is un ter using a spiral knife in the final stage of the Sche rens (S6) trimmed uniformly.

The poly (trimethylene terephthalate) carpet according to the invention has an excellent appearance, an excellent touch sensation, excellent wear resistance and elastic reset. These are the characteristics Advantages of nylon. The carpet still has a good fle resistance to corners and good electrostatic resistance What are the advantages of polyesters?  

Furthermore, the poly (trimethylene terephthalate) according to the invention lat) carpet a compressibility of 30% or more and ei ne compression recovery of 90% or more, pile yarns have a tensile strength of 2.0 kg or more. A bundle The cloth has a peel strength of 2.0 kg or more. Furthermore, the material has a color fastness to one Wash, a color fastness to rubbing and one Color fastness to light of grade 4 or more. Accordingly, is the poly (trimethylene terephthalate) according to the invention - Carpet as a high quality carpet for use suitable in living rooms or offices.

The invention is illustrated by the following examples purifies. These do not limit the present invention.

Test methods of the carpet (1) pencil point

The pencil point was determined with three ratings, i. H. A: good, B: medium, C: bad, using the naked eye The extent to which the ends of the pile frayed or through were chafed, was determined.

(2) Color fastness to rubbing

The color fastness to rubbing was according to the KS standard K 0650 determined.

(3) appearance

The color, the shine, the sense of volume, the touch The rugs' perception was based on four reviews averaged, d. H. AA: very good, A: good, B: medium, C: bad.  

(4) Stretch or tensile strength

The tensile strength was according to the KS standard K 0818 certainly.

(5) peel strength

The peel strength was determined in accordance with KS standard K 0818.

(6) Compressibility / compression recovery

The ratio of compressibility / compression springback was tested according to point A of KS standard K 0818.

(7) Color fastness to light

The carpet was treated at 63 ° C for 40 hours and after tested according to KS standard K 0700. Then the color fastness was checked determined against light using the ISO blue scale.

(8) Color fastness to washing

The carpet was treated at 40 ° C and according to point A-1 KS 0430 tested.

(9) Strip properties

The properties of the strips were determined with the naked eye in fol based on three ratings: A: good, B: medium, C: bad.

EXAMPLE 1

PTT polymer with a moisture content of 40 ppm and a fundamental molar viscosity of 0.92 was below at 250 ° C  Use of a nozzle with a Y-shaped cross section, 68 holes, a modification ratio of 2.0 and an arm angle of 33 ° in a Barmag spinning machine that weighs three tons spun yarns per day, melt spun to Produce 68 continuous yarns with 1300 denier. Then the resulting continuous yarns abge to 16 ° C in a cooling zone cools while the fancy yarns a speed of 0.5 m / min. After that, the cold continuous yarns under Ver using a feed roller with a temperature of 60 ° C and a speed of 700 m / min and a pull roller with a temperature of 160 ° C and a speed of 2300 m / min stretched.

The drawn yarns were crimped at 200 ° C in a texturing unit, cooled to 16 ° C in a cooling drum, and the cooled yarns were provided with 20 twists / m at 4.0 kg / m ² in a condenser and finally at 1950 m / min wound, whereby poly (trimethylene terephthalate) (BCF) yarns with a modified cross section were obtained.

Using a cable or yarn twisting device, the resulting BCF yarns were twisted at 194 twists / m Z-. The twisted yarns were then heat-cured in a Superba machine. Twisted yarns with a density of 240 g / m were heat-cured at a main tunnel temperature of 138 ° C and a belt speed of 5.14 m / min (6 m / 70 sec). The thermoset yarns were then applied to a polypropylene base cloth using a 1/10 gauge tufting machine. The pile was of cut pile style with a height of 12 mm, 13 stitches / 2.54 cm and a weight of the untreated yarn of 4 kg / 3.3 m ² .

The tufted or tufted carpet was carried without a carrier with a disperse dye DIANIX Combi under conditions  Atmospheric pressure, dyeing temperature of 98 ° C, dispersion medium 0.5 g / l, OWF value (amount of dye added based on the carpet) of 0.01% and a liquid ver Ratio of 20: 1 vat-colored.

The colored carpet was then coated with a mixture of 35% base latex, 60% CaCO ₃ dispersant and an agent to increase the viscosity. He was then glued to a second base cloth, ie jute, and finally shaved using a spiral knife. The resulting carpet was tested for appearance, pencil point and color fastness to rubbing. The results are summarized in Table 2.

EXAMPLES 2 TO 3

The procedure of Example 1 was repeated with the exception that the main tunnel temperature, the belt speed and the density of the untreated yarn were varied according to Table 1 . The resulting carpet was tested for its physical properties. The results are summarized in Table 2.

COMPARATIVE EXAMPLES 1 TO 4

To compare the physical properties of carpets, at which the heat curing conditions were varied the untreated yarns according to Example 1 at the company conditions as described in Table 1 below, heat hardened. Then the thermoset yarns of a Bü scouring, coloring, reinforcement and shear on the back stage in the same manner as in Example 1 to make a carpet. The resulting carpet was tested for its physical properties. The results nisse are summarized in Table 2.  

TABLE 1

TABLE 2

The carpet of Example 1 has an excellent appearance and excellent color fastness to rubbing the Rating 5. The ends of the pile were not frayed. Overall, the carpets also had the examples len 2 and 3 excellent physical properties.  

However, the carpet of Comparative Example 1 had one short thermal treatment low heat curing properties and he was hardly able to handle frictional forces withstand. The ends or edges of the pile were also quickly frayed. On the other hand, had a carpet with one long thermal treatment as in the comparative examples 2 and 3 very high heat curing properties and low Vo lumen properties as well as a bad sensation of touch. Because of the poor coloring properties he also had a bad look.

EXAMPLE 5 AND COMPARATIVE EXAMPLES 5 TO 6

To determine the tensile and peel strengths of pile, the according to the interval between stitches during the Curling or tufting had been varied, the exact te procedure of Example 1 repeated in Example 5. In the case of Comparative Examples 5 and 6, the procedure Example 1 repeated with the exception that the heat-hardened yarn on a polypropylene base cloth three stitches / 2.54 cm or 20 stitches / 2.54 cm were applied the.

The resulting poly (trimethylene terephthalate) carpet was tested for its physical properties and the Er Results are shown in Table 3.  

TABLE 3

In the case of Comparative Example 5, the adhesives were different not enough on the carpet during the back ver stratified because the interval between the sti Chen was too narrow, so that the tensile and peel strength ver were wrestled. Also with 20 stitches / 2.54 cm as in the Ver same example 6 described the appearance properties as the weight, the feeling of density and the feeling of touch very bad, although the tensile and peel strengths are not were bad.

EXAMPLE 6

The procedure of Example 1 was the exception repeats that a color base bath with 3% based on a PTT basic chip was added to the raw materials to produce dyed poly (trimethylene terephthalate) yarn len. A carpet was made in this way.

The carpet, which is made of spun-dyed poly (trimethylene terephthalate) yarns had been produced according to Example 3, was compared with the physical properties Carpet compared according to Example 1. The results are in Table 4 compiled.  

TABLE 4

The spun-dyed BCF carpet of Example 6 had one out more drawn color fastness to washing, to to the light and to the rubbing as a carpet, one Piece staining had been subjected. He had minor better strip properties than the product of the example 1, so the color properties of the spin-dyed carpet were better than an ordinary carpet. However, that was spun-dyed carpet in terms of compressibility and the compression recovery is a little worse because of a color level and the increase in latent text was missing was not present due to the coloring level. ever however, the compressibility and compression back were better suspension of the dyed carpet of the invention than those of a nylon or poly (ethylene terephthalate) - Carpet.

As expressed above, the present invention with a poly (trimethylene terephthalate) carpet marked properties in terms of appearance, loading touch, wear resistance, elastic Springback, stain resistance, electrostatic Resistance as well as peel strength, tensile strength and of dimensional stability. Furthermore, this has been invented Process according to the invention for producing the poly (trimethylene  terephthalate) carpet advantages in terms of an outstanding post-processing property.

Claims (11)

1. A process for producing a poly (trimethylene terephthalate) carpet comprising the steps:

• A) twisting or twisting poly (trimethylene terephthalate) yarns;
• B) Heat hardening of the twisted or twisted poly (trimethylene terephthalate) yarns with a density of 200 to 240 g / m using a Superba machine at a main tunnel temperature of 120 to 160 ° C and a belt speed of 4 to 9 m / min;
• C) tufts or tufts of the heat-cured poly (trimethylene terephthalate) yarns at 5 to 15 stitches / 2.54 cm;
• D) vat dyeing of the tufted, unsupported carpet using a disperse dye under conditions of atmospheric pressure and dyeing temperature of 90 to 100 ° C;
• E) reinforcing the colored carpet on the back; and
• F) shearing the resulting carpet.

2. The method according to claim 1, characterized records that dyed poly (trimethylene tereph thalat) yarns are used. 3. The method according to claim 1 or 2, characterized records that the twist level or Verdre level by Z-twisting or Z-twisting of the yarns  at 180 to 250 twists / m to a two or three layered rope is performed. 4. The method according to claim 1 or 2, characterized records that there is a stage of compaction of the bottom ly (trimethylene terephthalate) yarns using a Mixing machine at 400 to 1000 m / min under an air pressure from 4 to 8 bar without a heat setting level. 5. The method according to claim 1 or 2, characterized records that it continues to be the level of a frieze work before thermosetting. 6. The method according to claim 1 or 2, characterized records that the pile height ranges from 4 to 18 mm for a cut pile carpet and is in the range of 2.5 up to 15 mm for a loop pile carpet. 7. The method according to claim 1 or 2, characterized records that the tufted carpet in conditions an OWF value (amount of dye added, based on the carpet) from 0.01 to 3%, a liquid ratio nis from 10: 1 to 25: 1 and an amount of a dispersion is dyed by means of 0.25 to 1.0 g / l. 8. The method according to claim 1 or 2, characterized records that it continues the level of space color bens the poly (trimethylene terephthalate) yarns in one color or in six or less colors using a multi-color dyeing machine before the heat curing stage includes. 9. The method according to claim 1 or 2, characterized in that the colored carpet is coated with a latex composition consisting of 30 to 50% base latex, 50 to 70% CaCO ₃ , a dispersant and an agent to increase the viscosity, and that this is followed by the attachment to a second base fabric in the step of reinforcing on the back. 10. The method according to claim 1 or 2, characterized records that the poly (trimethylene terephthalate) - Carpet made from poly (trimethylene terephthalate) yarns which have been spun through a nozzle, wel che 40 or more holes, a Y-shaped cross section Modification ratio from 1.5 to 3.5 and an arm angle from 5 to 40 °. 11. Poly (trimethylene terephthalate) carpet made by the method of claim 1, the pile yarn with a Stretch or tensile strength of 2.0 kg or more and one on it bonded fabric with a peel strength of 2.0 kg or has more, as well as a color fastness to washing, one Color fastness to rubbing and color fastness compared to Korean rating 4 or more light Has technical standards.